Intake manifold with an intercooler

ABSTRACT

An intake manifold for a charged internal combustion engine has an intercooler provided with coolant connectors that is disposed in an intake manifold housing. The intake manifold housing has at least two housing parts including a basic housing part. The intake manifold housing is provided with at least one inlet and at least one outlet for charge air and is further provided with at least one passage for the coolant connectors of the intercooler. The intercooler is arranged between the at least one inlet and the at least one outlet so as to be flowed through by the charge air. The intercooler is fastened in the basic housing part by a fastening device such that the intercooler separates at least on one side of the basic housing part the at least one inlet seal-tightly from the at least one outlet.

BACKGROUND OF THE INVENTION

The invention concerns an intake manifold with an intercooler of acharged internal combustion engine, in particular of a motor vehicle,comprising an intake manifold housing that is assembled of at least twohousing parts, that comprises at least one inlet and at least one outletfor charge air, at least one passage for coolant connectors of theintercooler, and in which the intercooler is arranged between the atleast one inlet and the at least one outlet so as to be flowed throughby charge air.

WO 2008/061692 A1 discloses a modular component group of a turbo-chargedinternal combustion engine. The modular component group comprises anintake manifold and a heat exchanger for the intake air. The modularcomponent group comprises a housing which together with a cover definesa volume in which the heat exchanger is arranged. The housing comprisesan inlet for the intake air. The intake manifold socket opens toward acylinder head of the internal combustion engine through outlets for theintake air at a front side of the housing. The intake air flows throughthe heat exchanger. The heat exchanger is connected with a coolantcircuit.

It is an object of the invention to design an intake manifold of theaforementioned kind such that an air flow through the intake manifold,in particular through the intercooler, is further improved. Inparticular, cooling of the charge air with the intercooler is to befurther improved.

SUMMARY OF THE INVENTION

This object is solved according to the invention in that the intercooleris attached to a basic housing part of the intake manifold housing bymeans of a fastening device such that it separates at least on one sideof the basic housing part the at least one inlet seal-tightly from theat least one outlet.

According to the invention, the intercooler is attached within the basichousing part. It can be pre-mounted within the basic housing part. Theintercooler can be first fixedly positioned upon pre-assembly in thebasic housing part. Subsequently, at least one additional housing part,in particular a cover housing part, can be connected with the basichousing part for closing off the intake manifold housing. In this way,the assembly of the intake manifold can be simplified as a whole.Moreover, the additional housing part can be accordingly designed moresimply. The fastening device and the appropriate forces can engagesubstantially directly on the basic housing part. By attachment by meansof the fastening device, can be moreover prevented in a simple way thatthe intercooler after assembly of the intake manifold, in particularduring transport, during assembly at the internal combustion engine, orin operation of the intake manifold, will change its position within theintake manifold housing. By means of the fastening means the intercoolercan be mounted precisely in the basic housing part. In this way,possibly required mounting tolerances of the intercooler, in particularof a cooler housing of the intercooler, can be appropriately reduced inthe basic housing part. The intercooler can be arranged simply in thebasic housing part such that at least one of its exterior sides, inparticular an exterior side of its cooler housing or a flange plate, cancontact seal-tightly on at least one appropriate inner side of the basichousing part. In this way, it can be prevented that charge air can flowbetween the intercooler and the at least one inner side of the basichousing part and thus can bypass the intercooler. The charge air insteadmust pass through a heat exchanger area of the intercooler. The coolingeffect can be improved in this way.

The intake manifold housing can be arranged in its operating positionsuch that the basic housing part is located spatially at the bottom. Inthis way, the weight of the intercooler can press against thecorresponding inner side of the basic housing part. In this way, thesealing function can be further improved. Moreover, the correspondingfastening means can be relieved mechanically. Accordingly, the fasteningmeans can be dimensioned smaller.

The intake manifold can advantageously be part of an internal combustionengine with an exhaust gas turbocharger. With the intercooler, chargeair which is coming from a compressor of the turbocharger can be cooledbefore it is supplied to the cylinders of the internal combustionengine.

The intercooler can advantageously comprise a heat exchanger throughwhich a coolant can flow. The intercooler can advantageously comprise aradiator block which is flowed through by the coolant. In the radiatorblock, a heat exchange between the charge air and the coolant can takeplace. The intercooler can advantageously be a so-called plate-typecooler. The coolant can be advantageously a liquid coolant, inparticular cooling water or cooling water provided with additives. Thecoolant can be cooled in an area outside of the intake manifold by meansof a cooling circuit which extends out of the intake manifold housing.The coolant can advantageously be supplied through the correspondingcoolant connectors to the intercooler and can be carried away form it.

Advantageously, the cooler housing of the intercooler can restseal-tightly with a wall that extends circumferentially relative to amain axis of the intercooler on the corresponding inner side of thebasic housing part. In this way, the circumferential side of theintercooler can be sealed off in a simple way. The main axis can bedefined such that it passes through an inlet side and an outlet side ofthe intercooler. It can indicate roughly the average flow direction inwhich the charge air is supplied to the intercooler and is flowing outof it.

The cooler housing can comprise advantageously a flange plate. Theflange plate can be advantageously connected fixedly to the coolerhousing, in particular brazed. The flange plate can be advantageouslyresting seal-tightly on the corresponding inner side of the basichousing part.

The invention is not limited to an intake manifold of an internalcombustion engine of a motor vehicle. Instead, it can also be used indifferent types of internal combustion engines, in particular industrialmotors.

In an advantageous embodiment, the intercooler, when the intake manifoldis assembled, can separate seal-tightly the at least one inlet and theat least one outlet relative to all housing parts adjoining theintercooler. In this way, it can be prevented that the charge air canbypass the intercooler. In this way, a forced flow through theintercooler can be achieved. The cooling action of the charge air canthus be further improved.

Advantageously, the intercooler can be surrounded completely by theintake manifold housing. The intercooler can be completely disposedinside the intake manifold housing. In this way, all surfaces of thecooler housing of the intercooler can be loaded pressure-neutrally.Moreover, sealing means for sealing the intercooler relative to theenvironment can be dispensed with. Sealing of the intake manifoldhousing can be realized more simply.

Advantageously, the housing parts, in particular the basic housing partand the corresponding cover housing part can be integrally materialbonded to each other, in particular welded, in particular hot gaswelded, and/or glued. Alternatively or additionally, the housing partscan be connected to each other by at least one positive-lockingconnection and/or a frictional connection, in particular a screwconnection, a locking connection, and/or a plug connection.

Advantageously, at least one of the housing parts, in particular thebasic housing part and the cover housing part, can be made of plasticmaterial. Plastic parts can be connected easily with each other, inparticular by welding. Also, plastic parts can be produced simply, inparticular molded.

In the areas in which the intercooler is arranged seal-tightly in thebasic housing part, a separate sealing device is not required. As awhole, in this way the expenditure with regard to sealing means, inparticular seals, and/or mounting expenditure can be reduced.

In a further advantageous embodiment, the intercooler can be attached bymeans of at least one fixed bearing and at least one floating bearing onthe basic housing part.

While fixed bearings in the meaning of the invention enable movementonly for the purpose of fixation of the attachment, in particular arotational movement, floating bearings enable prior to fixation, inaddition to the movement for the purpose of fixation of the attachment,also sliding of components relative to each other that are to beconnected to each other. In this way, the components can be positionedrelative to each other, in particular in order to compensate possiblecomponent tolerances and/or mounting tolerances. Also, tolerancesoccurring during operation by component deformation and thermalexpansions as a result of different thermal expansion coefficients ofintercooler and component can be compensated in this way. The at leastone floating bearing is thus characterized in that, up to the point ofits fixation, it enables a tolerance compensation. By means of a fixedbearing a connection without preload loss can be realized. Theconnection with a fixed bearing can be advantageously designed for theservice life of the participating components without preload loss.

The at least one fixed bearing and the at least one floating bearing canbe advantageously located on opposite sides of the intercooler. In thisway, the intercooler can be stably and precisely fixed by means of theat least one fixed bearing on one side. On the other side, theintercooler can be attached with positional tolerance by means of the atleast one floating bearing.

The at least one fixed bearing can be located advantageously on the sideof the basic housing part on which also the at least one inlet and/orthe at least one outlet are located. The at least one floating bearingcan be advantageously located on the side that is facing away from theat least one inlet or the at least one outlet.

The at least one fixed bearing can advantageously comprise a connectionthat is rotatable and/or insertable. The at least one fixed bearing canbe advantageously an insert bushing, in particular a bushing for use inhot areas or a bushing which is embedded by injection molding in thematerial of the component. The insert bushing can be advantageouslymounted in an appropriate hole in the basic housing part, in particular,pressed in. The insert bushing can be advantageously provided with aninner thread. Into the inner thread a screw member, in particular ascrew, with an appropriate outer thread can be screwed in. The screwmember can be advantageously connected without clearance with theintercooler. The screw member can be in particular mounted in anappropriate receptacle of the intercooler, in particular pushed througha through opening. The receptacle, in particular the opening, canadvantageously optionally be provided in the flange plate of the coolerhousing of the intercooler.

Instead of the screw connection also a different type of rotationaland/or insertable connection between the intercooler in the insertbushing can be realized. Instead of the screw also an appropriatedifferent type of rotation/insertion element can be used. In particular,a bayonet-like connection can also be provided. Instead of the insertbushing, an insert with a bolt, in particular a threaded bolt, can beprovided also. The bolt can be secured accordingly within the receptacleof the intercooler. It can be inserted through a through opening at theintercooler and fixed on an opposite side by means of the fixationelement, in particular a screw nut.

Advantageously, the insert bushing and/or the appropriaterotation/insertion element, in particular the screw, can be made ofmetal. In this way, a metallic connection can be realized. Metallicconnections have a higher stability and robustness and a reduced preloadloss in comparison to connections between components of plastic witheach other or components of plastic with components of metal. This canimprove in particular the reliability of the intake manifold when usedin connection with lifetime components.

The at least one floating bearing can comprise advantageously arotational and/or insertable connection. Advantageously, a screwconnection can be provided. Advantageously, the at least one floatingbearing can comprise a screw that is in particular thread-forming. Thescrew can advantageously be screwed into an appropriate hole in thebasic housing part. The screw can be secured, on the other hand, in anappropriate receptacle of the intercooler. It can be inserted through anappropriate opening at the intercooler. Advantageously, the opening canbe arranged optionally in the flange plate of the cooler housing. It canadvantageously be located in a flange of the flange plate. The screw ofthe floating bearing can be arranged in the receptacle in the non-fixedstate of the connection so as to allow clearance. At least in onedirection transverse to the axis of the screw, the receptacle can beadvantageously provided with an inner diameter that is greater than theouter diameter of the screw. Advantageously, the receptacle can be aslotted hole. The floating bearing is fixed only once therotational/insertion connection is fixed.

Thread-forming screws have the advantage that they can be screwedwithout generating chips into the hole of the basic housing part. Incontrast to self-cutting screws, thread-forming screws do not cut thematerial of the base housing part. Instead of the thread-forming screws,the at least one floating bearing can also comprise different types ofscrews, in particular self-cutting ones. As an alternative, also athread or a thread insert in or on the basic housing part can beprovided into which an appropriate screw, in particular a machine screw,can be screwed. Instead of the screw connection also a different type ofrotation/insertion connection, in particular a bayonet-type connectionor a locking connection, can be provided. Instead of the screws, pinscan be used also. The pins can be in particular hot-riveted.

In a further advantageous embodiment, at least one captive action devicecan be provided for securing at least one rotation/insertion element ofthe at least one fixed bearing and/or the at least one floating bearing.In this way, it can be prevented that the at least onerotation/insertion element after assembly, in particular in operation ofthe intake manifold, can fall out of its receptacle.

Advantageously, the at least one captive action device can comprise atleast one rib. The at least one rib can be advantageously connected tothe other housing part, in particular the cover housing part. The atleast one rib can be advantageously monolithically connected with theother housing part. It can be advantageously injection-molded onto theother housing part.

The at least one captive action device can advantageously be provided ona side opposite the at least one rotation/insertion element from whichside the rotation/insertion element is introduced into the appropriatereceptacle. The at least one captive action device can be arranged suchthat, upon assembly of the housing parts, it interacts automaticallywith the appropriate rotation/insertion element in a securing manner.The at least one captive action device, in case that the appropriaterotation/insertion element, in particular upon transport or duringoperation of the intake manifold, should become released, can provide amechanical stop for the rotation/insertion element. Advantageously, whenusing screws, an undesirable unscrewing of the corresponding screws canbe prevented by means of the at least one captive action device.

In a further advantageous embodiment, the basic housing part cancomprise the at least one inlet and/or the at least one outlet and/orthe at least one passage for the coolant connectors. In this way, theother housing parts which are used for closing off the intake manifoldhousing can be designed simpler. Moreover, the appropriate components,in particular the intercooler and/or the connectors, can be assembledsimply in the basic housing part. The assembly of the intake manifoldcan thus be further simplified.

Advantageously, the basic housing part can comprise a mounting devicefor mounting the intake manifold housing on the internal combustionengine and/or a frame part, optionally of the motor vehicle. Inparticular, appropriate mounting flanges can be arranged on the exteriorside of the basic housing part. In this way, a stable securing action ofthe intake manifold on the internal combustion engine and/or on theframe part can be realized. Moreover, a reliable and stable forcetransmission between the intercooler, the basic housing part, and theinternal combustion engine and/or the frame part can also be realized inthis way.

Advantageously, the at least one outlet can be designed such that it canbe immediately connected with a cylinder head of the internal combustionengine. For this purpose, the at least one outlet can be arranged in atleast one appropriate connecting flange. The connecting flange canadvantageously be connected by means of a rotation/insertion connection,in particular at least one threaded bolt or at least one screw, to thecylinder head. The at least one connecting flange can be advantageouslyarranged on the basic housing part. Advantageously, it can be connectedmonolithically to the basic housing part.

Advantageously, the intake manifold housing can be combined of twohousing parts. It can be advantageously in the form of two shells, inparticular a top shell and a bottom shell. Advantageously, the basichousing part can be the bottom shell. The cover housing part can be thetop shell.

At least the basic housing part can have dished walls. In this way, thewalls can be mechanically stabilized. The dished walls can beadvantageously curved in all directions. Advantageously, the dishedwalls can be curved outwardly from an interior of the intake manifoldhousing to the exterior. Advantageously, all housing parts can havedished walls. Advantageously, all walls of the intake manifold housingcan be dished. In this way, the stability in particular pressureloadability of the intake manifold housing can be further improved.

In a further advantageous embodiment, at least one of the housing wallsof the intake manifold housing can have at least one corrugation. The atleast one corrugation can contribute to reinforcement of the at leastone housing wall of the intake manifold housing. It can further improvethe stability of the intake manifold housing.

The at least one corrugation can be advantageously a depression or abulge of the at least one housing wall. It can be a trough-shapeddepression in the at least one housing wall. A corrugation wall of theat least one corrugation can be advantageously approximately in the formof a section of a cylinder wall, in particular of a circular cylinderwall.

The at least one corrugation can extend in longitudinal directionadvantageously transversely to the main axis of the intercooler. The atleast one corrugation can extend between the inlet side of theintercooler and the outlet side in the direction of a width of theintercooler that extends transversely to the main axis.

A corrugation wall of at least one inner corrugation can advantageouslyextend into an interior of the intake manifold housing. In this way, thecorrugation wall of the inner corrugation can impair a flow of thecharge air past the intercooler, in particular reduce it. The at leastone inner corrugation can advantageously extend in its longitudinalextension across the entire appropriate extension, in particular width,of the intercooler, optionally of a flange plate of the intercooler.

In a further advantageous embodiment, an exterior side of a corrugationwall of at least one inner corrugation which is facing the intercoolercan rest seal-tightly on the corresponding exterior side of theintercooler, optionally of the flange plate of the intercooler. In thisway, the sealing action between the intercooler and the housing wall ofthe intake manifold housing can be improved. The corrugation wall of theat least one inner corrugation can advantageously be extending acrossthe entire width of the intercooler, optionally the flange plate, on thecorresponding exterior side of the intercooler, in particular the flangeplate. In this way, the area between the intercooler and thecorresponding housing wall of the intake manifold housing can be sealedacross the entire width of the intercooler, in particular of the flangeplate.

Advantageously, the corrugation wall of the at least one innercorrugation provided on the housing base member can be restingseal-tightly on the exterior side of the intercooler, optionally of theflange plate. In this way, on the side of the housing base member asealing action can be realized without a separate sealing element, inparticular a separate seal, being required.

Alternatively or additionally, a corrugation wall of at least one outercorrugation on the intake manifold housing can extend advantageouslyoutwardly.

In a further advantageous embodiment, a corrugation wall of at least oneinner corrugation, with its side that is facing the intercooler, can bespaced apart from the corresponding exterior side of the intercooler. Anappropriate gap between the corrugation wall and the exterior side of acooler housing of the intercooler can be provided. The gap can serve asa tolerance compensation. With it, appropriate manufacture-relatedand/or assembly-related and/or operation-related tolerances can becompensated.

Advantageously, on one side of the intercooler, the corrugation wall ofthe at least one inner corrugation can rest on the corresponding housingwall and, on the opposite side of the intercooler, the corrugation wallof at least one oppositely positioned inner corrugation can be spacedapart from the oppositely positioned housing wall of the intercooler.

In a further advantageous embodiment, in or on at least one corrugationat least one reinforcement rib can be arranged. The at least onereinforcement rib can be advantageously arranged within the at least onecorrugation. The at least one reinforcement rib can stabilize thecorrugation wall of the at least one corrugation. It can contribute tostiffening of the intake manifold housing. It can improve the stabilityof the intake manifold housing. The at least one reinforcement rib canbe advantageously extending across the length extension of the at leastone corrugation. It can advantageously be arranged approximately at thecenter of the at least one corrugation. It can advantageously bisect theat least one corrugation.

The at least one reinforcement rib can advantageously extend radially toa longitudinal axis of the at least one corrugation. It can be extendingadvantageously perpendicularly to the corresponding exterior side of theintercooler, in particular the housing wall of the cooler housing or theflange plate.

Should the corrugation wall of the at least one corrugation extend fromthe interior of the intake manifold housing to the exterior, i.e., aninner corrugation is concerned, the at least one reinforcement rib canextend as an inner reinforcement rib into the interior of the intakemanifold housing. The at least one inner reinforcement rib can thusdisturb a flow of the charge air past the cooler housing of theintercooler, in particular reduce it.

Inasmuch as the corrugation wall of the at least one corrugation extendsinto the interior of the intake manifold housing, i.e., an outercorrugation is concerned, the at least one reinforcement rib can belocated as an outer reinforcement rib on the exterior side of the intakemanifold housing.

In a further advantageous embodiment, the at least one innerreinforcement rib can be supported with its free rim on an appropriateexterior side of the intercooler. In this way, the stability of theintake manifold, in particular of the intake manifold housing, can befurther improved. Moreover, the securing action of the intercooler inthe intake manifold housing can be improved. Advantageously, the atleast one inner reinforcement rib can be supported seal-tightly on theexterior side of the intercooler. In this way, the sealing action can befurther improved thereat.

The at least one inner reinforcement rib can be located advantageouslyon the housing base member. Advantageously, the at least one innerreinforcement rib can be supported on the flange plate or the housingwall of the cooler housing.

In a further advantageous embodiment, at least one inner reinforcementrib, with its free rim, can be spaced apart from the correspondingexterior side of the intercooler. It is possible to have correspondinggaps thereat. The gaps can be serving as tolerance compensation. In thisway, corresponding manufacture-related and/or installation-relatedand/or operation-related tolerances can be compensated. The at least oneinner reinforcement rib can be located advantageously on the sideopposite the housing base member. The free rim of the at least one innerreinforcement rib, with its free rim, can advantageously be spaced apartfrom the corresponding housing wall of the cooler housing of theintercooler.

The at least one inner reinforcement rib can extend advantageouslyacross the entire width of the intercooler. In this way, a disturbanceof the flow of the charge air, in particular a sealing action, acrossthe entire width of the intercooler can be realized.

Advantageously, at least one inner reinforcement rib with its free rimcan be resting on one side on the exterior side of the intercooler and,on the opposite side of the intercooler, the free rim of at least oneopposite inner reinforcement rib can be spaced apart from thecorresponding exterior side of the intercooler. In this way, on one sideof the intercooler in a simple way a sealing action of a space betweenthe intercooler and the corresponding wall of the manifold housing canbe improved. At the same time, a tolerance compensation can be realizedon the other side of the intercooler.

Advantageously, the free rim of the at least one inner reinforcement ribcan be resting on the exterior side of the intercooler on the same sidewhere the corresponding corrugation wall of the at least one innercorrugation is resting also.

Advantageously, the free rim of the at least one inner reinforcement ribcan be spaced apart from the exterior side of the intercooler on thesame side where also the corresponding corrugation wall of the at leastone inner corrugation is spaced apart.

Advantageously, the at least one housing wall of the intake manifoldhousing can be resting only along the corrugation wall of the at leastone inner corrugation and/or the free rim of the at least one innerreinforcement rib on the exterior side of the intercooler. This can havea positive effect on noise development during operation of the internalcombustion engine.

Advantageously, several corrugations and/or several reinforcement ribscan be positioned adjacent to each other, in particular parallel to eachother, in at least one housing wall of the intake manifold housing.Alternatingly, outer corrugations and inner corrugations can bearranged. The corrugations can advantageously realize a corrugatedcourse of the housing wall. Advantageously, the corrugations can beprovided alternatingly with an outer reinforcement rib and an innerreinforcement rib. The stability of the intake manifold housing can thusbe further improved as a whole.

The height of the at least one corrugation can be advantageously betweenapproximately 10 mm and approximately 20 mm. The height of the at leastone corrugation can advantageously extend approximately perpendicularlyto the exterior side of the intercooler. A corresponding height of theat least one reinforcement rib can be approximately between 10 mm and 20mm.

In a further advantageous embodiment, a corrugation wall of at least onecorrugation in the area of an inlet side or an outlet side of theintercooler can have a flow contour. In this way, the flow course of thecharge air into the intercooler or out of it can be improved.Advantageously, the corrugation wall of the at least one corrugation canproject past the intercooler at its inlet side or its outlet side atleast in a rim area. In this way, it can be prevented that charge air atthe corresponding inlet side or the outlet side can bypass theintercooler. In this way, possible turbulences on the inlet side or theoutlet side of the intercooler can be reduced. The charge air can thusflow directly and uniformly into a heat exchanger area, in particular,into a corresponding radiator block, of the intercooler or out of it. Atthe inlet side as well as at the outlet side of the intercooler,corrugation walls with corresponding flow contours can be provided.Accordingly, corresponding flow contours can be provided on the sidewhich is facing the basic housing part as well as on the side which isfacing the other housing part of the intercooler on the inlet sideand/or the outlet side.

In a further advantageous embodiment, the corrugation wall of the atleast one corrugation can form at least partially a seal receptacle fora sealing device. The sealing device can be arranged in a space-savingway in the seal receptacle. By means of the sealing device an areabetween the housing wall of the intake manifold housing and theintercooler, in particular the housing wall of the cooler housing of theintercooler, can be sealed additionally. The corrugation wall with theseal receptacle can be advantageously located outside of the area of thebasic housing part in which the housing wall of the intake manifoldhousing is resting seal-tightly on the exterior side of the intercooleranyway. The corrugation wall with the seal receptacle can advantageouslybe located on the side of the intercooler where corrugation walls ofpossible further inner corrugations are spaced apart from the exteriorside of the intercooler. In this way, by means of the sealing device anadditional sealing action and/or tolerance compensation can be realized.

In a further advantageous embodiment, between at least one exterior sideof the intercooler and a corresponding housing wall of the intakemanifold housing at least one seal can be arranged. The at least oneseal can be advantageously located on at least one exterior side whichis circumferential relative to the main axis of the intercooler. The atleast one seal can advantageously be located on the side of theintercooler which is facing away from the housing base member.Advantageously, on the side which is facing the housing base member noseparate seal is provided. The at least one seal can be advantageouslylocated on the side of the intercooler where a corrugation wall of atleast one possible inner corrugation and/or a free rim of at least oneinner reinforcement rib is spaced apart from the corresponding exteriorside of the intercooler.

The at least one seal can advantageously be elastic. In this way, it cansimply adjust to the shape and/or the course of the correspondingexterior side of the intercooler, in particular the housing wall of thecooler housing. Moreover, in this way it can act as a tolerancecompensation and/or vibration damping means. Advantageously, the sealcan be realized of a foam with closed or open surface. Advantageously,the at least one seal can be circumferentially open relative to the mainaxis of the intercooler. In this way, it can be arranged on theintercooler even after attachment of the intercooler in the housing basemember.

The at least one seal can be advantageously U-shaped. In this way, itcan cover at least partially a side, in particular a top side, of theintercooler that is facing the housing base member or facing away fromit as well as the corresponding lateral exterior sides of theintercooler. At least one leg of the U-shaped seal can project into aninterior and/or a corresponding receptacle in the wall of the housingbase member. In this way, it can seal the corresponding lateral exteriorside of the intercooler relative to a corresponding sidewall of thehousing base member.

Advantageously, the at least one seal can be mounted on the housing partwhich is different from the housing base member, in particular on thecover member, in particular pre-mounted. The housing part for closingoff the intake manifold housing after attachment of the intercooler inthe housing base member can be placed onto the housing base member orinserted into it. In doing so, the seal with the housing part can beautomatically properly positioned.

In a further advantageous embodiment, in at least one housing part thatserves for closing off the housing base member, at least one seal holderfor the at least one seal can be arranged. The at least one seal holdercan be advantageously designed as a sealing rib. On, at or in the atleast one seal holder, the at least one seal can be pre-mounted. The atleast one seal holder can be advantageously monolithically formed withthe housing part. The at least one seal holder can extendcircumferentially relative to the main axis of the intercooler. The atleast one seal holder can advantageously be approximately U-shaped. Inthis way, the at least one approximately U-shaped seal can be simplysecured.

The at least one seal holder can advantageously be arranged sectionwisein a corresponding receptacle, in particular groove, of thecorresponding housing part. In this way, the at least one seal holdercan be arranged at a defined spacing to the exterior side of theintercooler. With the defined spacing to the cooler housing of theintercooler, transitions of legs of the at least one, in particularU-shaped, seal holder and the at least one, in particular U-shaped, sealcan be realized in a simple way also for larger radii of curvature.

Advantageously, the at least one seal holder can have a T-shaped profileat least in the area of the lateral circumferential wall of theintercooler. The at least one seal holder can thus be mechanicallystabilized. In this way, a free-standing seal holder can be realizedalso.

Advantageously, the at least one seal holder and/or the at least oneseal, in particular at least one corresponding leg, can project at leastsectionwise past a rim, in particular a fastening flange or a weldingflange, of the corresponding housing part. In this way, the projectingsection, in particular leg, of the at least one seal holder and/or theat least one seal can be inserted into a corresponding holdingreceptacle of the housing base member. The holding receptacle can berealized in particular in or on at least one of the sidewalls of thehousing base member. The holding receptacle can be designed as a grooveof sorts.

The at least one seal can have on its side that is facing away from theintercooler an approximately U-shaped profile. The U-shaped profile candefine a receptacle, in particular a holding rib receptacle for the atleast one seal holder, in particular a leg. The leg of the at least oneseal holder can be inserted into the receptacle of the at least oneseal. In particular, a radial section of the seal holder can be arrangedin the receptacle.

On at least one free end which is facing the housing base member, the atthe at least one seal holder, in particular at least one leg of the sealholder, can comprise advantageously a seal securing groove. The at leastone seal can have on the corresponding end face of the corresponding enda corresponding seal securing web. The seal securing web can engage theseal securing groove when the seal is mounted. In this way, it can beprevented that the at least one seal upon assembly of the housing partsis stripped or pulled off the seal holder.

Instead of the seal securing groove and the seal securing web, the sealcan also be provided with a different type of captive securing action.Advantageously, the side of the seal which is pushed on or inserted intothe seal holder can have a corresponding profile, in particular with anundercut, which can engage a corresponding counter profile of the sealholder. In this way, the seal can also be realized from a continuousprofile.

The at least one seal can advantageously have an approximately Y-shapedprofile. In this context, the two upper legs of the Y-shaped profile canbe facing the exterior side of the intercooler. Upon mounting on theintercooler, the upper legs of the Y-shaped profile can be spread apart.They can thus bridge correspondingly large gaps between the housing wallof the intake manifold housing and the exterior side of the intercooler.The Y-shaped profile enables a simple tolerance compensation across acorrespondingly large range.

At least one end of the at least one seal can be provided with a bevelin the area of at least one of the two upper legs of the Y-shapedprofile. A bevel in this context is to be understood as a slantedsurface in the area of an edge. In this way, upon assembly of thehousing parts of the intake manifold housing, the insertion of the atleast one seal on the intercooler can be simplified.

Alternatively or in addition, an opening angle between the upper legs ofthe Y-shaped profile can be enlarged toward at least one end of theseal. In this way, the assembly can be further simplified.

Alternatively or in addition, the length of at least one of the upperlegs of the Y-shaped profile of the at least one seal can be variablydesigned. In areas of possible larger operation-related deformations ofthe intake manifold housing, in particular in the central areas of theseal, a safer sealing action can be realized by means of longer legs.

In a further advantageous embodiment, the at least one seal can bemounted, in particular premounted, also on the intercooler, inparticular the cooler housing, instead of on the housing part. The atleast one seal can advantageously be glued to the intercooler, inparticular the cooler housing.

Advantageously, the at least one seal can be designed to be symmetric,in particular in circumferential direction. In this way, it is notrequired to pay attention to a mounting orientation. False installationof the at least one seal can thus be prevented.

BRIEF DESCRIPTION OF THE DRAWINGS

Further advantages, features, and details of the invention will resultfrom the following description in which an embodiment of the inventionwill be explained in more detail with the aid of the drawing. A personof skill in the art will consider features that are disclosed incombination in the drawing, the description, and the claims alsoexpediently individually and combine them to further meaningfulcombinations.

FIG. 1 shows in isometric illustration an intake manifold of aturbo-charged internal combustion engine of a motor vehicle, comprisingan intake manifold housing in which an intercooler is arranged, in aview at a slant from above.

FIG. 2 shows the open intake manifold of FIG. 1 without cover shell.

FIG. 3 shows the intake manifold of FIG. 1 in a view at a slant frombelow.

FIG. 4 shows the open intake manifold of FIG. 2 in a plan view.

FIG. 5 is a detail of a horizontal longitudinal section of the intakemanifold of FIG. 1 in the area of a fixed bearing with which theintercooler is attached to a bottom shell of the intake manifoldhousing.

FIG. 6 is a detail of a vertical cross-section of the intake manifold inthe area of the fixed bearing of FIG. 5 along the section line VI-VIindicated therein.

FIG. 7 is a detail of a horizontal longitudinal section of the intakemanifold of FIG. 1 in the area of two floating bearings with which theintercooler is attached to the bottom shell.

FIG. 8 is a detail of a vertical cross-section of the intake manifold inthe area of a floating bearing of FIG. 7 along the indicated sectionline VIII-VIII.

FIG. 9 is a vertical longitudinal section of the intake manifold of FIG.1 along a section line IX-IX of FIG. 4.

FIG. 10 is a first detail view of the longitudinal section of FIG. 9.

FIG. 11 shows a second detail view of the longitudinal section of FIG.9.

FIG. 12 is a third detail view of the longitudinal section of FIG. 9.

FIG. 13 is an isometric illustration of the top shell of the intakemanifold housing of the intake manifold of FIG. 1 in a view of theinterior.

FIG. 14 is a detail view of the top shell of FIG. 13 in the area of aholding rib for a seal not indicated here.

FIG. 15 shows the detail view of FIG. 14 with the seal.

FIG. 16 is a horizontal longitudinal section of the intake manifold ofFIG. 1 through the top shell in the area of the holding rib with theseal.

FIG. 17 is a vertical longitudinal section of the intake manifold ofFIG. 1 through the top shell in the area of the holding rib with theseal.

In the Figures, the same components are identified with same referencecharacters.

DESCRIPTION OF PREFERRED EMBODIMENTS

In the FIGS. 1 to 17, an intake manifold 10 of an internal combustionengine of a motor vehicle charged with an exhaust gas turbocharger isillustrated in various perspective views, sections, and detailed views.

For better orientation, in the Figures the corresponding axes of arectangular X-Y-Z coordinate system are indicated. In the describedembodiment, the z-axis extends in the normal installed position of theintake manifold 10, illustrated in FIG. 1, in vertical spatial directiondownwardly. The x-axis and the y-axis define a horizontal plane which isin the following referred to as X-Y plane. The x-axis and the z-axisdefine an X-Z plane. The y-axis and the z-axis define correspondingly aY-Z plane.

When in the following “top”, “bottom”, “front”, or “rear” is used, thisrefers to the illustration of FIG. 1, if not indicated otherwise. Thespatial arrangement of the intake manifold 10, as illustrated in FIG. 1,corresponds in general to the installed state in the motor vehicle. Theinstalled state of the intake manifold 10 may however be deviating fromit. For example, the intake manifold 10 can also be mounted in reverse.

The intake manifold 10 is arranged in an intake system for combustionair of the internal combustion engine that is connected to an outlet ofa compressor of the turbocharger.

The intake manifold 10 comprises an intake manifold housing 12 in whichan intercooler 14 is arranged. The intercooler 14 serves for cooling thecharge air which is coming from the compressor of the turbocharger andflows through the intake manifold housing 10. The intake manifold 10serves for distributing the charge air onto the corresponding cylindersof the internal combustion engine. In the present embodiment, the intakemanifold 10 serves for distributing the charge air onto four cylindersof the internal combustion engine.

The intake manifold housing 12 is assembled of a connecting shell 16, inFIG. 1 at the bottom, and a top shell 18, at the top. The connectingshell 16 and the cover shell 18 are made of plastic material. Theexterior walls of the intake manifold housing 12 are curved or bentoutwardly, i.e., dished, in their basic shape.

An interior of the intake manifold housing 12 comprises an intakechamber 20, a cooler chamber 22, and an outlet chamber 24 which arearranged one behind the other with regard to a flow passage of thecharge air through the intake manifold housing 12. The flow path throughthe intake manifold housing 12 is indicated in FIGS. 1 to 7 and 9 to 12by arrows 26.

The connecting shell 16 has at the side of a lower inlet-sidelongitudinal wall 34, in FIGS. 1 and 2 at the front, an inlet 28 for thecharge air. The inlet 28 is arranged in the area of a transition of theinlet-side longitudinal wall 34 into an inlet-side transverse side 40 ofthe intake manifold housing 12. The inlet 28 opens into the inletchamber 20. The inlet chamber 28 extends in the direction of the y-axisacross the width of the cooler chamber 22.

Immediately behind the inlet 28 there is a two-part partition section 30in the inlet chamber 20 which extends approximately parallel to the Y-Zplane. The partition section 30 separates a part of the inlet chamber 20at the front, when viewed from the inlet 28, from the cooler chamber 22.The bottom part of the partition section 30 is connected monolithicallywith the connecting shell 16. A top part of the partition section 30 isconnected monolithically with the cover shell 18.

The inlet 28 is surrounded by an inlet connector flange 32. The inletconnector flange 32 is monolithically connected with the connectingshell 16. With the inlet connector flange 32, a connection to an inletline of the intake system of the internal combustion engine whichextends to the outlet of the compressor of the turbocharger can berealized by means of screw connections. In the inlet line, for example,a throttle valve can be arranged.

A mounting flange 38 is monolithically connected with the connectingshell 16 in the area of the lower inlet-side longitudinal wall 34 and alower rearward longitudinal wall 36, respectively. The mounting flange38 is located on the exterior side of the connecting shell 16approximately at the level of a transition of the inlet chamber 20 intothe cooler chamber 22. The mounting flanges 38 each extend approximatelyparallel to the X-Y plane. By means of the mounting flanges 38, theintake manifold 10 can be connected by means of a screw, respectively,to a corresponding frame part of the internal combustion engine.

On an outlet-side transverse side 42 of the intake manifold housing 12that is opposite the inlet-side transverse side 40, the connecting shell16 has four lower distributor tube sections 44 adjacently arrangedrelative to the flow path 26. The lower distributor tube sections 44form each a bottom part of a respective distributor tube 46. Eachdistributor tube 46 opens into the outlet chamber 24. The outer chamber24 serves as a distributing chamber for distributing the charge air ontothe four distributor tubes 46. The distributor tubes 46 each comprise attheir free ends an outlet 48 for the charge air. The outlets 48 of thedistributor tubes 46 are surrounded by a common outlet connector flange50. The outlet connector flange 50 is respectively monolithicallyconnected with the lower distributor tube sections 44. By means of theoutlet connector flange 50, the distributor tubes 46 are connected,respectively, to the corresponding inlets, not shown, of the cylindersof the internal combustion engine by means of screws.

A rim of the connecting shell 16 which is facing the cover shell 18 isdesigned as a bottom welding flange 52. The bottom welding flange 52surrounds externally the inlet chamber 20, the cooler chamber 22, theoutlet chamber 24, and the lower distributor tube sections 44. When theintake manifold 10 is assembled, the lower welding flange 52 is weldedto the top welding flange 54 of the cover shell 18. In the area of theinlet chamber 20 and of the cooler chamber 22, the weld seam extendsbetween the bottom welding flange 52 and the top welding flange 54approximately in a plane that is parallel to the X-Z plane, asillustrated, for example, in FIG. 9.

The lower longitudinal walls 34 and 36 have each in the area of thecooler chamber 22 in the vicinity of the transition to the outletchamber 24 a groove-shaped holding receptacle 56. The holdingreceptacles 56 serve each for receiving a respective leg of a holdingrib 58. The holding rib 58 serves for securing a seal 60. The holdingribs 58, as shown, for example, in FIGS. 13 to 15, are attached to thecover shell 18. The holding receptacles 56 are each realized as outerbulges with an approximately U-shaped profile in the longitudinal walls36 and 38. The holding receptacles 56 extend each approximately in thedirection of the z-axis. The holding receptacles 56 are each open acrossthe entire height toward the cooler chamber 22. They each have anundercut on either end of the open side which is facing the coolerchamber 22.

In a bottom side 64 of the connecting shell 16 two coolant connectors 66of the intercooler 14 are arranged. By means of the coolant connectors66 the intercooler 14 is supplied with appropriate coolant, for example,cooling water.

The bottom side 64, as shown, for example, in FIGS. 3 and 9 to 11, hasin the area of the cooler chamber 22 a corrugated course in thedirection of the x-axis. The corrugated extension is realized by a totalof three lower inner corrugations 68 which are alternatingly arrangedwith four lower outer corrugations 70, 71. The lower corrugations 68,70, and 71 are groove-shaped depressions in the bottom side 64. Thelower corrugations 68, 70, and 71 each extend with their longitudinalaxes approximately parallel to the y-axis. They extend across the entirewidth in the direction of the y-axis of the cooler chamber 22.

Respective corrugation walls of the lower inner corrugations 68 eachhave approximately the profile of a section of a circular cylinder wallwhose open side is pointing away from the cooler chamber 22 in outwarddirection. The corrugation walls themselves extend into the coolerchamber 22, therefore the name “inner corrugations”. The lower innercorrugations 68 themselves are outwardly open.

Respective corrugation walls of the two central lower outer corrugations70 have also approximately the profile of sections of circular cylinderwalls whose open sides are open toward the interior of the coolerchamber 22, respectively.

The corrugation height 72, which is indicated in FIG. 9, is betweenapproximately 10 mm and approximately 20 mm, preferably approximately 15mm. The corrugation height 72 corresponds to a spacing between therespective apexes of the corrugation walls of the lower innercorrugations 68 and the central lower outer corrugations 70.

The corrugation wall of the inlet-side lower outer corrugation 71 thatis facing the inlet chamber 20 has on the side that is facing the inletchamber 20 a lower inlet-side flow contour 74. The lower inlet-side flowcontour 74 fits snuggly a lower inlet-side end face edge of a flangeplate 76 of a cooler housing 78 of the intercooler 14. The lowerinlet-side flow contour 74 extends across the entire width of the coolerchamber 22 in the direction of the y-axis. It forms a ramp of sorts forthe flow of the charge air to the inlet side 80 of the intercooler 14.The lower inlet-side flow contour 74 forms a smooth transition from theinlet chamber 22 into the inlet side 80 of the intercooler 14.

A corrugation wall of the outlet-side lower outer corrugation 71 has alower outlet-side flow contour 82 that is similar to the lowerinlet-side flow contour 74 and forms a smooth transition from the outletside 84 of the intercooler 14 to the outlet chamber 24. The loweroutlet-side flow contour 82 engages about a corresponding loweroutlet-side end face edge of the flange plate 76.

The flange plate 76 is brazed onto a bottom side of the cooler housing78 which is facing the bottom side 64 of the connecting shell 16. Theflange plate 76 is flat and extends approximately parallel to the X-Yplane. The flange plate 76 is positioned with its exterior side acrossthe entire width in the direction of the y axis seal-tightly on the legsof the corrugation walls of the lower inner corrugations 68. Also, thelower inlet-side end face edge and the lower outlet-side end face edgeof the flange plate 76 are seal-tightly positioned at the correspondinglower flow contours 74 and 82. In this way, no charge air can flow belowthe flange plate 76 past the exterior side of the intercooler 14.

Moreover, on the bottom side 64 of the connecting shell 16 on the innerside which is facing the cooler chamber 22 two lower inner transversereinforcement ribs 86 are arranged. The lower inner transversereinforcement ribs 86 extend each within one of the two central lowerouter corrugations 70 from their bottom to the exterior side of theflange plate 76. They end approximately at the same height as the apexesof the corrugation walls of the neighboring lower inner corrugations 68.The lower inner transverse reinforcement ribs 86 extend eachapproximately parallel to the Y-Z plane. The lower inner transversereinforcement ribs 86 are located each approximately centrally withinthe corresponding lower outer corrugations 70. Their free rims are eachpositioned seal-tightly on the exterior side of the flange plate 76.

Moreover, two lower outer transverse reinforcement ribs 88 are arrangedon the bottom side 64 of the connecting shell 16 on the exterior side ofthe intake manifold housing 12 which is facing away from the coolerchamber 22. The lower outer transverse reinforcement ribs 88 extend eachapproximately parallel to the lower inner transverse reinforcement ribs86. One of the lower outer transverse reinforcement ribs 88 ispositioned in the interior of the inlet-side lower corrugation 68. Thesecond lower outer transverse reinforcement ribs 88 is arranged in theinterior of the central lower inner corrugation 68. The lower outertransverse reinforcement ribs 88 each are located approximatelycentrally in the corresponding corrugations 68. In the illustration ofthe FIGS. 2 and 3, the illustration of the lower outer transversereinforcement ribs 88 has been omitted for better clarity.

Moreover, the bottom side 64 of the connecting shell 16 has at itsexterior side a plurality of lower outer longitudinal reinforcement ribs90. The lower outer longitudinal reinforcement ribs 90 extend eachapproximately parallel to the X-Z plane. They end in the direction ofthe z-axis in the area of the central lower outer corrugations 70approximately at the level of the apexes of the corrugation wallspositioned thereat. In the direction of the x-axis, the lower outerlongitudinal reinforcement ribs 90 extend across the inlet chamber 20,the cooler chamber 22, and the connecting chamber 24.

In FIGS. 1, 4, and 5, on the exterior side of the lower inlet-sidelongitudinal wall 34 of the connecting shell 16 several lateralreinforcement ribs are illustrated additionally that each extendapproximately parallel to the Y-Z plane. In the other Figures, theselateral reinforcement ribs are not shown for better clarity.

Moreover, viewed in the direction of the x-axis, in the area of thelower inlet-side longitudinal wall 34 of the connecting shell 16approximately centrally in the cooler chamber 22 a blind bore, shown inFIG. 6, is arranged. The blind bore is open at the side which is facingthe cover shell 18. An insert bushing 92 is inserted into the blindbore. The axes of the blind bore and the insert bushing 92 are parallelto the z-axis. The insert bushing 92 is made of metal. It has an innerthread for a corresponding outer thread of a fastening screw 94. Thefastening screw 94 is also made of metal. The threads of the insertbushing 92 and of the fastening screw 94 can be preferably metric.Alternatively, also other types of threads can be provided.

The fastening screw 94 extends through a corresponding hole in theflange plate 76 of the intercooler 14. An inner diameter of the holecorresponds approximately to the outer diameter of the fastening screw94. The fastening screw 94 is arranged relative to a plane that isparallel to the X-Z plane, i.e., radial to its axis, without play in thehole.

The fastening screw 94 and the insert bushing 92 form a fixed bearing96. The fixed bearing 96 serves for fastening the intercooler 14 in theconnecting shell 16. The attachment is stationary relative to the planethat is parallel to the X-Z plane and without preload loss. Byconnecting the fastening screw 94 of metal with the insert bushing 92 ofmetal, a fixed connection is provided which maintains its preload evenfor an extended period of time, preferably for its service life.

Below corresponding semi-circular cylindrical bulges of the lowerrearward longitudinal wall 36, two screw holes 98 are arranged in theconnecting shell 16 for a thread-forming screw 100, respectively. Thescrew holes 98 are open, respectively, toward the cover shell 18. Theaxes of the screw holes 98 extend approximately parallel to the z-axis.One of the screw holes 98 is located approximately at the side of thecooling chamber 22 which is opposite the fixed bearing 96. The otherscrew hole 98 is located in the vicinity of the inlet chamber 20.

The thread-forming screws 100 extend through corresponding holes in theflanges of the flange plate 76 of the intercooler 14. The respectivediameter of the holes is greater than the corresponding outer diameterof the thread-forming screws 100. As long as the thread-forming screws100 are not tightened yet they are movable radially relative to theirrespective axis in the holes of the flange plate 76. The screw holes 98with the respective thread-forming screws 100 form a floating bearing102, respectively. With the floating bearings 102 the intercooler 14 isfastened in the connecting shell 16. The enlarged holes in the flangeplate 76 enable a position-tolerant mounting on this side of theintercooler 14.

The cover shell 18, shown, for example, in detail in FIG. 13, has fourupper distributor tube sections 104. When the intake manifold 10 isassembled, the upper distributor tube sections 104 close off one of thelower distributor tube sections 44 of the connecting shell 16,respectively, and thus form part of one of distributor tubes 46,respectively.

Moreover, the cover shell 18 has an inlet cover section 106 which closesoff a corresponding lower inlet section of the inlet 28 at the side ofthe connecting shell 16.

A topside 108 of the cover shell 18, shown at the top in FIGS. 1 and 9,is corrugated similar to the bottom side 64 of the connecting shell 16.It has a total of three upper inner corrugations 110 and 111 and fourupper outer corrugations 112 and 114. The two central upper corrugations112, the inlet-side upper outer corrugation 114, the inlet-side upperinner corrugation 110, and the central upper inner corrugation 110 arepositioned, relative to a mirror plane which is parallel to the X-Yplane, approximately mirror-symmetrical to the corresponding lowercorrugations 68, 70, and 71.

A corrugation wall of the inlet-side upper outer corrugation 114 has anupper inlet-side flow contour 116 which engages, similar to the lowerinlet-side flow contour 78, the upper inlet-side end face edge of thecooler housing 78. It forms in this way a smooth flow transition fromthe inlet chamber 22 into the inlet side 80 of the intercooler 14.

At a transition between the corrugation walls of the outlet-side upperinner corrugation 111 and the outlet-side upper outer corrugation 114, aseal holder bay 118 is realized which is illustrated in FIG. 17 indetail. The seal holder bay 118 is open toward the cooler chamber 22. Inthe seal holder bay 118, viewed in the direction of the x-axis, a radialsection 120 of the holding rib 58 is approximately centrally arrangedand is radial to the main axis 52 of the intercooler 14. The radialsection 120 extends approximately in a plane parallel to the Y-Z plane.

The main axis 62 extends through the inlet side 80 and the outlet side84 of the intercooler 14. The main axis 52 indicates roughly the averageflow of the charge air into the intercooler 14 at the inlet side 80 andout of the intercooler 14 at the outlet side 84. The main axis 52 is animaginary axis. It is only provided for the purpose of orientation. Itdoes not necessarily indicate precisely the average flow direction ofthe charge air through the intercooler 14. The main axis 52 extendsapproximately parallel to the x-axis.

The seal holder bay 118 extends into an upper inlet-side longitudinalwall 122 of the cover shell 18 and at the opposite side into an upperrear longitudinal wall 124 of the cover shell 18. The lateral legs ofthe seal holder bay 118 provided in the upper longitudinal walls 122 and124 each have an undercut at the open side that is facing the coolerchamber 22.

As a whole, the holding rib 58, viewed in the direction of the x-axis,is approximately U-shaped. Lateral legs of the holding rib 58 projecteach freely into the corresponding lateral legs of the seal holder bay118. The lateral legs of the holding rib 58 extend approximatelyparallel to the z-axis. The lateral legs of the holding rib 58 eachproject past the upper welding flange 54. When the intake manifoldhousing 12 is assembled, the lateral legs of the holding rib 58 projectinto the respective holding receptacles 56 of the connecting shell 16.

The lateral legs of the holding rib 58 have each a T-shaped profilewherein the lower leg of the T-profile forms the radial section 120. Atthe transitions of the lateral legs to a horizontal section, the holdingrib 58 has an approximately round radius of curvature, respectively.

At the end faces of the free ends of the legs of the holding ribs 58,the respective radial section 120 is provided with a seal securinggroove 126 is provided, respectively. In FIG. 14 one of the sealsecuring grooves 126 is shown. As illustrated in FIG. 15, acorresponding seal securing web 128 engages in the seal securing groove126. The seal securing web 128 is located at the free ends of the legsof the seal 60, respectively.

At the inner side of the upper inlet-side longitudinal wall 122 that isfacing the cooler chamber 22 there is moreover a captive securing rib130 arranged at the fixed bearing. The fixed bearing-side captivesecuring rib 130 is monolithically connected with the longitudinal wall122 and the topside 108 of the cover shell 18. The fixed bearing-sidecaptive securing rib 130 has a cross-shaped profile. It extends in itslongitudinal direction approximately parallel to the z-axis and projectspast the upper welding flange 54. When the intake manifold housing 12 isassembled, the fixed-bearing side captive securing rib 130 is locatedapproximately at the opposite side, in the direction of the z-axis, ofthe screw head of the fastening screw 94 of the fixed bearing 96. An endface of the fixed bearing-side captive securing rib 130 is located nearthe screw head and prevents that the fastening screw 94 can unscrew fromthe insert bushing 92.

Likewise, on the side of the upper rearward longitudinal wall 124, in arespective bulge, two floating bearing-side captive securing ribs 132for securing the screws 100 of the floating bearings 102 are arranged.The floating bearing-side captive securing ribs 132 have each anapproximately L-shaped profile. A first one of the legs of the L-shapedprofile extends respectively on the side which is facing away from thecooler chamber 22 approximately in a plane parallel to the Y-Z plane.The other leg extends respectively approximately parallel to the X-Zplane and points away from the first leg toward the inlet chamber 20.

Moreover, the topside 108 of the cover shell 18 has at its inner side aplurality of upper inner longitudinal reinforcement ribs 134. The upperinner longitudinal reinforcement ribs 134 each extend in the area of thecooler chamber 22 approximately parallel to the X-Z plane.

Moreover, the topside 108 has at its inner side a plurality of upperinner transverse reinforcement ribs 140. The upper inner transversereinforcement ribs 140 extend approximately parallel to the Y-Z plane.The height of the upper inner longitudinal reinforcement ribs 134 andthe upper inner transverse reinforcement ribs 140 in the direction ofthe z-axis corresponds approximately to the corrugation height of thewave shape that is formed by the upper corrugations 110, 111, 112, and114. The upper inner transverse reinforcement ribs 140 are located eachwithin one of the central upper outer corrugations 112.

On the exterior side of the cover shell 18, a plurality of upper outerlongitudinal reinforcement ribs 143 and upper outer transversereinforcement ribs 142 are extending, respectively. The upper outerlongitudinal reinforcement ribs 143 extend each approximately parallelto the X-Z plane. The upper outer transverse reinforcement ribs 142extend each approximately parallel to the Y-Z plane. In accordance withthe outer lower transverse reinforcement ribs 88, in the interior spacesof the inlet-side and the central upper inner corrugation 110, an upperouter transverse reinforcement rib 142 is arranged, respectively.

In FIGS. 1 and 13, on the exterior side of the upper inlet-sidelongitudinal wall 122 of the cover shell 18 several additional lateralreinforcement ribs are additionally illustrated which extend eachapproximately parallel to the Y-Z plane. In the other Figures, theselateral reinforcement ribs are not shown for the purpose of betterclarity.

The seal 60 is made of an elastic material. The seal 60 has a Y-shapedprofile, as illustrated, for example, in FIGS. 15 to 17. The two upperlegs of the Y-shaped profile are oriented toward the correspondingexterior sides of the intercooler 14. The central leg of the Y-shapedprofile extends approximately in a plane parallel to the Y-Z plane. Itfaces toward the exterior side of the intake manifold housing 12. It hasa groove-shaped securing rib receptacle 136 which is open toward theexterior side of the intake manifold housing 12. The radial section 120of the holding rib 58 is inserted into the holding rib receptacle 136.

The seal 60 is approximately U-shaped when viewed in the direction ofthe x-axis. It is open at the side which is facing the bottom side 64 ofthe connecting shell 16 and extends circumferentially relative to themain axis 52. At the free ends of the legs of the seal 60 of which oneis shown in an exemplary fashion in FIG. 15, the holding rib receptacle136 is closed off with the seal securing web 128 provided thereat. Byengagement of the seal securing web 128 in the seal securing groove 126in the radial section 120 of the holding rib 58, the seal 60 is securedat its free end, respectively.

At the free ends of the legs of the seal 60, the two upper legs of theY-shaped profile are provided each with a bevel 138. The two upper legsof the Y-shaped profile have in their relieved state an opening angle ofapproximately 90 degrees.

The cooler housing 78 is circumferentially closed relative to the mainaxis 52 of the intercooler 14. The cooler housing 78 as a whole isapproximately parallelepipedal and open at the inlet side 80 and theoutlet side 84. The charge air to be cooled can flow in at the inletside 80 into a heat exchanger area of the intercooler 14, passes throughappropriate flow passage in which a heat exchange with the correspondingcooling medium takes place, and can flow out through appropriateopenings at the outlet side 84. The intercooler 14 can be, for example,a so-called plate-type cooler. In the heat exchanger area flow areas forthe charge air are fluid-tightly separated from flow areas for thecoolant and are thermally connected to each other.

On the side of the cooler housing 78 that is facing the lower inlet-sidelongitudinal wall 34 of the connecting shell 16 and the upper inlet-sidelongitudinal wall 122 of the cover shell 18, the cooler housing 78 has arecess 144. The recess 144 extends across the entire height of thecooler housing 78 in the direction of the z-axis. Due to the recess 144the fastening screw 94 of the fixed bearing 96 can be introduced.

In the assembled intake manifold 10, the apexes of the corrugation wallsof the upper inner corrugations 110 and 111 which are facing theintercooler 14, the free rims of the upper inner transversereinforcement ribs 140 and of the upper inner longitudinal reinforcementribs 134 are each spaced apart from the upper exterior side of thecooler housing 78 located thereat.

A sealing of the sidewalls and the top wall of the cooler housing 78relative to the inner side of the intake manifold housing 12 is realizedby means of seal 60 in a position-tolerant way.

For assembly of the intake manifold 10, the intercooler 14 is firstinserted with the coolant connectors 66 leading in the direction of thez-axis into the cooler chamber 22 of the connecting shell 16.

The fastening screw 94 of the fixed bearing 96 is screwed in through thecorresponding hole in the flange plate 76 into the thread of the insertbushing 32 and tightened up to the stop. The intercooler 14 is securedwith the fixed bearing 96 without preload loss for the lifetime in theconnecting shell 16.

Subsequently, the thread-forming screws 100 of the floating bearings 102are screwed in through the corresponding holes in the flanges of theflange plate 76 into the corresponding screw holes 98 of the connectingshell 16. The thread-forming screws 100 are tightened up to the stop.The intercooler 14 is thus also fixed at this side on the connectingshell 16. The floating bearings 102 may have over their lifetime apreload loss.

The lower flow contours 74 and 82, the apex of the corrugation walls ofthe lower inner corrugations 68, and the rims of the lower innertransversely extending transverse reinforcement ribs 86 are positionedseal-tightly on the exterior side of the flange plate 76. In this way,no charge air can bypass the intercooler 14.

Subsequently, the cover shell 18 is mounted from above in the directionof the z-axis onto the connecting shell 16. In this context, the freelegs of the holding ribs 58 and the seal 60 are inserted into thecorresponding holding receptacles 56 of the connecting shell 16. Thebevels 138 simplify pushing on the seal 60 onto the cooler housing 78.The two upper legs of the Y-shaped profile of the seal 60 bend apart inthe direction of the x-axis. The two upper legs of the Y-shaped profileof the seal 60 snuggly fit the corresponding exterior sides of thecooler housing 78.

The end faces of the captive securing ribs 130 and 132 of the covershell 18 are located in the final mounted state of the cover shell 18 onthe corresponding heads of the fastening screws 94 and thethread-forming screws 100.

The connecting shell 16 and the cover shell 18 are welded to each otheralong the lower fastening flange 52 and the upper fastening flange 54.

The assembled intake manifold 10 is connected by means of the outletconnector flange 50 with the cylinders of the internal combustionengine. The intake manifold housing 12 is fastened with the fasteningflanges 38 on the frame part of the internal combustion engine. Theinlet connector flange 32 is connected with the inlet line.

While specific embodiments of the invention have been shown anddescribed in detail to illustrate the inventive principles, it will beunderstood that the invention may be embodied otherwise withoutdeparting from such principles.

What is claimed is:
 1. An intake manifold for a charged internalcombustion engine, the intake manifold comprising: an intercoolerprovided with coolant connectors; an intake manifold housing wherein theintercooler is disposed in the intake manifold housing; the intakemanifold housing comprising at least two housing parts including a basichousing part; the intake manifold housing provided with at least oneinlet and at least one outlet for charge air and further provided withat least one passage for the coolant connectors of the intercooler;wherein the intercooler is arranged between the at least one inlet andthe at least one outlet so as to be flowed through by the charge air;wherein the intercooler is fastened in the basic housing part by afastening device such that the intercooler separates at least on oneside of the basic housing part the at least one inlet seal-tightly fromthe at least one outlet.
 2. The intake manifold according to claim 1,wherein the intercooler, when the intake manifold is assembled,seal-tightly separates the at least one inlet and the at least oneoutlet relative to all of the at least two housing parts of the intakemanifold housing adjoining the intercooler.
 3. The intake manifoldaccording to claim 1, wherein the fastening device comprises at leastone fixed bearing and at least one floating bearing that fasten theintercooler on the basic housing part.
 4. The intake manifold accordingto claim 3, further comprising at least one captive action device thatsecures at least one rotation/insertion element of the at least onefixed bearing.
 5. The intake manifold according to claim 3, furthercomprising at least one captive action device that secures at least onerotation/insertion element of the at least one floating bearing.
 6. Theintake manifold according to claim 1, wherein at least one of the atleast one inlet, the at least one outlet, and the at least one passagefor the coolant connectors is arranged on the basic housing part.
 7. Theintake manifold according to claim 1, wherein the intake manifoldhousing has housing walls and at least one of the housing walls has atleast one corrugation.
 8. The intake manifold according to claim 7,wherein the at least one corrugation is an inner corrugation and has acorrugation wall with an exterior side, wherein the exterior side of thecorrugation wall faces the intercooler and rests seal-tightly on anexterior side of the intercooler that is facing the corrugation wall. 9.The intake manifold according to claim 8, wherein the exterior side ofthe intercooler is a flange plate of the intercooler.
 10. The intakemanifold according to claim 7, wherein the at least one corrugation isan inner corrugation and has a corrugation wall that faces theintercooler and is spaced apart from an exterior side of the intercoolerthat is facing the corrugation wall.
 11. The intake manifold accordingto claim 7, wherein in or on the at least one corrugation at least onereinforcement rib is arranged.
 12. The intake manifold according toclaim 11, wherein the at least one reinforcement rib is an innerreinforcement rib that has a free rim supported on an exterior side ofthe intercooler that is facing the free rim.
 13. The intake manifoldaccording to claim 11, wherein the at least one reinforcement rib is aninner reinforcement rib that has a free rim that is spaced apart from anexterior side of the intercooler that is facing the free rim.
 14. Theintake manifold according to claim 7, wherein the at least onecorrugation is arranged at an inlet side of the intercooler or an outletside of the intercooler and has a corrugation wall provided with a flowcontour.
 15. The intake manifold according to claim 7, wherein the atleast one corrugation has a corrugation wall that at least partiallyforms a seal receptacle for a seal device.
 16. The intake manifoldaccording to claim 1, further comprising at least one seal that isarranged between at least one exterior side of the intercooler and ahousing wall of the intake manifold housing that is facing the at leastone exterior side.
 17. The intake manifold according to claim 16,further comprising at least one seal holder for the at least one seal,wherein the at least two housing parts include a cover shell that closesoff the basic housing part, wherein the at least one seal holder isarranged on the cover shell.